EP0741079A2 - Procédé et dispositif de transport, d'inspection et d'emballage de lentilles de contact après l'hydratation - Google Patents

Procédé et dispositif de transport, d'inspection et d'emballage de lentilles de contact après l'hydratation Download PDF

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Publication number
EP0741079A2
EP0741079A2 EP96303006A EP96303006A EP0741079A2 EP 0741079 A2 EP0741079 A2 EP 0741079A2 EP 96303006 A EP96303006 A EP 96303006A EP 96303006 A EP96303006 A EP 96303006A EP 0741079 A2 EP0741079 A2 EP 0741079A2
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EP
European Patent Office
Prior art keywords
lens
packages
package
assembly
lenses
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP96303006A
Other languages
German (de)
English (en)
Other versions
EP0741079B1 (fr
EP0741079A3 (fr
Inventor
Wallace Anthony Martin
Ture Kindt-Larsen
Russell James Edwards
Borge Peter Gundersen
Darren Scott Keene
John Mark Lepper
Niels Jorgen Madsen
Thomas Christian Ravn
Daniel Tsu-Fang Wang
Masao Funo
William Edward Holley
Tomoichi Watanabe
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johnson and Johnson Vision Care Inc
Original Assignee
Johnson and Johnson Vision Products Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson and Johnson Vision Products Inc filed Critical Johnson and Johnson Vision Products Inc
Publication of EP0741079A2 publication Critical patent/EP0741079A2/fr
Publication of EP0741079A3 publication Critical patent/EP0741079A3/fr
Application granted granted Critical
Publication of EP0741079B1 publication Critical patent/EP0741079B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00038—Production of contact lenses
    • B29D11/00125—Auxiliary operations, e.g. removing oxygen from the mould, conveying moulds from a storage to the production line in an inert atmosphere
    • B29D11/0023—Transferring contact lenses
    • B29D11/0024—Transferring contact lenses using a vacuum suction gripper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B25/00—Packaging other articles presenting special problems
    • B65B25/008—Packaging other articles presenting special problems packaging of contact lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B35/00—Supplying, feeding, arranging or orientating articles to be packaged
    • B65B35/30—Arranging and feeding articles in groups
    • B65B35/36—Arranging and feeding articles in groups by grippers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
    • B65B5/08—Packaging groups of articles, the articles being individually gripped or guided for transfer to the containers or receptacles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
    • B65B5/10—Filling containers or receptacles progressively or in stages by introducing successive articles, or layers of articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B55/00—Preserving, protecting or purifying packages or package contents in association with packaging
    • B65B55/22—Immersing contents in protective liquids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00—Automatic control, checking, warning, or safety devices
    • B65B57/10—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M11/00—Testing of optical apparatus; Testing structures by optical methods not otherwise provided for
    • G01M11/02—Testing optical properties
    • G01M11/0207—Details of measuring devices
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M11/00—Testing of optical apparatus; Testing structures by optical methods not otherwise provided for
    • G01M11/02—Testing optical properties
    • G01M11/0207—Details of measuring devices
    • G01M11/0214—Details of devices holding the object to be tested
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0016—Lenses
    • B29L2011/0041—Contact lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B51/00—Devices for, or methods of, sealing or securing package folds or closures; Devices for gathering or twisting wrappers, or necks of bags
    • B65B51/10—Applying or generating heat or pressure or combinations thereof
    • B65B2051/105—Heat seal temperature control
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S134/00—Cleaning and liquid contact with solids
    • Y10S134/901—Contact lens

Definitions

  • the present invention relates generally to the field of manufacturing contact lenses. More particularly, the present invention relates to an apparatus which removes contact lenses from a first set of pallets, inserts them into corresponding packaging elements on a second set of pallets, and transports the lens-packaging elements through inspection and final package sealing assemblies.
  • each lens is formed by sandwiching monomer or monomer mixture between a front curve (lower) mold section and back curve (upper) mold section, carried in a two by four mold array.
  • the monomer is polymerized, thus forming a lens which is then removed from the mold sections and further treated in a hydration bath and packaged for consumer use.
  • U.S. Patent Nos. 5,080,839 and 5,094,609 disclose respectively a process for hydrating contact lenses and a chamber for hydrating contacts lenses formed with a monomer or monomer mixtures disclosed in the forgoing patents.
  • the process disclosed in these patents significantly reduce the thruput time by hydrating the lens and releasing the lens from the mold cavity with deionized water and a small amount of surfactant without any salts, so that the time consuming ionic neutralization of the polymer from which the lens blank is made does not occur during the hydration process.
  • the final step of the process is to introduce buffered saline solution into the final package with the lens and then seal the lens within the package so that the final lens equilibrium (ionic neutralization, final hydration and final lens dimensioning) is accomplished in the package at room temperature or during sterilization.
  • U.S. Patent No. 4,961,820 also assigned to the assignee of the present invention, discloses a final package for a contact lens, wherein the package is formed from a transparent plastic material such as polypropylene and a foil laminate that is heat sealed thereto.
  • a manufacturing assembly line may include apparatuses for both the manufacture of a product and of packaging therefor.
  • apparatuses may be provided which are directed to the insertion of the product into the packaging and/or to the inspection of the product.
  • recent developments in the inspection of contact lenses produced in accordance with the foregoing methods has enabled automated lens inspection, as taught in EP-A-0 605 171.
  • recent developments in the hydration and automated handling of wet contact lenses, as taught in EP-A-0 686 488 has enabled automatic robotic handling of lenses during hydration, and prior to the inspection thereof by the automated lens inspection system.
  • Automated manufacturing processes often include steps which are particularly sensitive to interruption. For example, with respect to the manufacture of contact lens mold sections, the successful molding of thermoplastic elements having sufficiently correct optical surfaces requires that temperature fluctuations in the molding station remain steady. Other apparatuses in manufacturing lines, however, are subject to frequent interruption; requiring resupplies of materials, substitution of parts, etc. For example, materials for manufacturing packaging materials may be supplied in segmented rolls which, once depleted must be replaced.
  • the present invention is directed to the portion of the contact lens assembly line in which: a pallet of packaging elements are filled with a quantity of deionized water; a set of contact lenses, which have been molded, hydrated, and washed, are removed from a pallet and inserted into their respective packaging elements; the combined set of packaging elements and respective lenses are transported to a buffering station; the set of elements are transferred to a low vibration conveyor line; the contact lenses are inspected for flaws; the deionised water is removed from the packages; the combined elements are removed from their pallets, the packages containing flawed lenses are deposited on a conveyor line which deposits the elements in a collection bin, and the packages containing correct lenses are deposited on a good line; the lenses on the good line are consolidated into a regular array and transported onto a pallet; and a quantity of saline solution is introduced into the packages and a foil cover is heat sealed to the package.
  • the deionized water injector assembly is a device for injecting a quantity of deionized water into packaging elements on a pallet.
  • This deionized water injector assembly is mounted above a conveyor line along which pallets of regularly arrayed packaging elements are transported from a remote fabrication location to the second location where they receive contact lenses.
  • the spatial distribution of the regular array of the packaging elements is specifically established to match the optical array in the inspection station.
  • the lens extraction and insertion assembly of the present invention is a lens transfer device which lifts lenses from hydration pallets at a first location and deposits them, along with an additional dose of deionized water, into the packaging elements at the second location. In addition to transferring the lenses, the device also alters the spatial distribution of the lenses from their orientation in the hydration pallets to an orientation which corresponds to the packaging elements (and the lens inspection station).
  • the hydration pallets comprise a set of concave recessions in which the lenses are disposed, along with a quantity of deionized water.
  • the bottom of the recessions comprise at least one hole through which a fluid may be ejected, therein lifting the wet lenses out of the recessions.
  • the lens transfer assembly comprises a set of elongate finger elements which extend downward, each finger element having a convex lens transfer surface onto which the lifted lens may be secured via surface tension.
  • the convex lens transfer surface of the finger is further designed with an annular raised skirt around the tip which prevents the lens from sliding out of the desired position during transfer.
  • the lenses which have been transferred to the convex lens transfer surfaces on the fingers of the lens transfer device may have small bubbles of air on their exposed surface.
  • the small bubbles if permitted to remain on the surface of the lens through the inspection process may interfere with proper inspection, and cause the lens to be improperly determined to be bad, and discarded unnecessarily.
  • At least one jet of air is blown onto each lens for the purposes of removing the air bubbles from this exposed surface.
  • the fingers of the lens transfer assembly are set out in rows on parallel beams which are slidably mounted on guide rails.
  • the parallel beams are coupled together via piston/ cylinder elements, and are drawn together once the lenses have been extracted and the bubble blow off step have been carried out. This action alters the relative separation of the lenses with respect to one axis, so that the lenses will be arrayed to match the array provided by a lens inspection pallet.
  • the lens transfer assembly then is linearly translated to the second location, into position above the inspection pallet.
  • the fingers of the lens transfer assembly are further designed with an interior conduit, extending from a small orifice in the lens transfer surface of the finger to a reservoir of deionized water, through which deionized water may be selectively ejected. With the fingers, and the lenses secured thereto, in position above the packages, a small jet of deionized water is ejected through each orifice, therein decoupling the contact lenses from the lens transfer surfaces and depositing them into the packages that were loaded in the inspection carrier.
  • the pallet and the package elements which now contain contact lenses are then transported via a conveyor belt to a buffering station. More specifically, the pallets are transported to a segregating apparatus, which directs alternating pallets onto parallel conveyor lines.
  • the conveyor lines extend a sufficient distance, from their first ends to their remote ends, that a significant temporal delay may be accommodated, and the lenses stored without requiring stopping the molding line which requires a long start up time.
  • the buffering station taught in EP-A-0 686 585 is positioned after the inspection station, at a point in the manufacturing line where the packages containing the lenses have been drained of deionized water. Deprived of a liquid environment, the lenses are permitted to stand for no longer than 15 minutes before rejection thereof. Moving the buffering station to a point in the line at which the lenses remain bathed in deionized water permits indefinite holding without damaging the lenses.
  • the parallel conveyor lines of the buffering station have, mounted to their end (the end toward which the pallets are transported), a device which selectively merges the two streams of pallets so that they may pass onto the next conveyor.
  • the conveyor lines which transport the pallets to the buffering station and which extend after the buffering station are co-linear and immediately adjacent to a first one of the two parallel conveyor lines.
  • the segregator device therefore, first allows a single pallet to advance onto the first buffer line, and then transfers the next pallet to the parallel second buffer line.
  • the integrator device operates by permitting one pallet from the first buffer line to pass, then transports a pallet from the second buffer line to the conveyor line which continues beyond the buffering station so that it may follow, and then begins anew by allowing the next pallet from the first buffer line to pass.
  • the segregator and integrator devices continually or selectively divide and consolidate the stream of pallets along the two buffer lines.
  • the stream of pallets is divided by the segregator and consolidated by the integrator at all times during the operation of the manufacturing line.
  • the segregator and integrator are engaged only under circumstances when the subsequent stations have been interrupted.
  • the segregator of this alternative variation would operate only during interrupted times; the integrator would function past the resumption of the subsequent assemblies until there are no more pallets on the second buffer line. It is understood that there are a variety of alternative buffering algorithms which the segregator and integrator devices may utilize for separating and bringing together the pallets, all of which are equivalent in function and exist within the scope of this invention.
  • the stream of pallets which continue from the buffering station are transported to a pickup location. At this location the pallets are lifted off the conveyor line by a low vibration pallet transfer assembly and placed on a low vibration conveyor.
  • the low vibration conveyor transports the pallets through the inspection station wherein a determination is made of the optical properties of the hydrated and packaged lenses. It is understood that the proper inspection of the lenses may not occur if the perceived optical properties of the lenses are distorted by air bubbles which have adhered to the surface of the lenses. Waves and disturbances within the deionized water in the packages have a similar distortion effect, causing false determinations of defects.
  • the low vibration conveyor line therefore, provides a means for minimizing the distortions resulting from water disturbances.
  • the reduction in speed of the stream of pallets along the low vibration conveyor line must be compensated by a corresponding increase in the density of the pallets moving therealong.
  • the low vibration pallet transfer assembly therefore, places successive pallets adjacent to one another on the low vibration line, such that the spacing between the pallets is substantially reduced from the previous conveyor lines.
  • Determination of the optical correctness of each lens in each pallet is stored in the memory of a controller/processor so that subsequently a means for separating the good lenses from the bad may be utilized.
  • the pallets which contain packages filled with deionized water are transported to a water extraction assembly. Only after the optical correctness of the lenses has been determined may the proper saline solution be introduced into the package. The delay in introducing the saline solution until after the lenses have been inspected permits the line to proceed much more quickly, as, as stated above, the optical and physical characteristics of the lens requires several hours in the saline solution to equilibrate. It is understood that this equilibration is advantageously carried out in the sealed packages, once the lenses have been removed from the manufacturing line.
  • a light beam or pulse is directed from sources onto the lens-packages, received by a vertical lens unit, and directed and focused on a screen to produce an image of the lens.
  • the image is converted to an electrical information signal which is processed to determine if the lens is acceptable for consumer use.
  • the lens inspection results are stored in the programmable logic controller which coordinates subsequent consolidation and transfer assemblies.
  • the packages are transported along the conveyor line to a lens-package pickup point. At this location the packages are lifted by a lens-package transfer assembly from the pallets and moved to alternative conveyor lines. More particularly, there are alternative variations of the lens-package transference assembly; a first in which the lens-package elements are all removed from the pallets, and a second in which only those packages which contain a correct lens are removed. It is understood that the first variation transports the packages over to a reject conveyor line, and pauses during transport to deposit any incorrectly formed lenses and the packages in which they are disposed. The assembly then transports the remaining correctly formed lenses and packages to the good conveyor line.
  • the lens-package transfer assembly removes only the properly formed lenses and packages from the pallets and transports them to the good conveyor line. Any rejected lenses are then removed from the inspection pallets in a subsequent collection procedure.
  • the determinations made by the inspection assembly which were stored in memory by a processor/controller are herein acted upon by the lens-package transfer assembly.
  • a set of bellowed fingers, extending downward from a vacuum manifold are first positioned directly above the packages on a pallet.
  • the processor/controller may either control the selective pickup of the optically correct lens-packages, or the assembly may pick up all of the lens-packages. In either case, the desired lens-packages are transported to the good conveyor line, where the vacuum is released and the lens packages are dropped from the tips of the fingers.
  • the array of lens-packages which are ultimately deposited onto the good conveyor line are not necessarily in a regular array, as they were on the pallet (having had the incorrectly formed lens-package elements removed).
  • the good line therefore, also carries out a consolidating function, whereby the lens-packages are brought back together into a regular distribution. More specifically, the conveyor line carries the articles into separate corral structures. A first lens-package is conveyed between converging guide rails (which align the lens-package along one axis of motion), and into a corral. The first lens-package in line is stopped by a gate at the distal end. The next lens-package follows the lead one and is stopped by coming in contact with the first. Once a predetermined number of lens-packages have entered the corral, and a regular array of lens-packages has been established, the lens-packages are removed from the conveyor line and deposited onto a final packaging pallet.
  • the lens-package elements are removed from the corral, into which they have been directed by a conveyor line, by a rotating lens-package transfer assembly.
  • This assembly comprises an array of bellowed fingers, similar in most respects to those of the lens-package transfer assembly, which lift the array of lens-package elements and places them onto pallets.
  • the assembly further includes a rotational motion which rotates the array of elements to match the orientation of the pallets used for primary packaging.
  • the pallets are incrementally translated into position beneath a saline solution deposition unit.
  • This unit comprises a row of fluid dispensers which fill the packages with saline solution.
  • a buffered saline solution is injected into each of the packages and each of the lenses begins its equilibration process, matching the tonicity of a human eye (which has an equivalent salinity).
  • the pallets continue forward and are sealed with a foil wrapper. More particularly, with respect to the device which applies and seals the foil wrapper to the package, an elongate section of foil wrapper material is advanced through a printer (for printing information pertaining to the particular lens specifications). The foil is then cut into sections which are sized to fit across the tops of an array of packaging elements. The foil sections and the lens-package assemblies are advanced into alignment with one another. A vacuum gripper head grasps a foil section and descends to the package elements, placing the section in contact therewith. Once the foil wrapper is in position, a sealing mechanism is brought into contact with the packages and heat seals the foil to the package in a single high temperature short cycle sealing operation. The sealed packages are then advanced beyond the sealing assembly where they may be stored during equilibration, and ultimately packaged for distribution.
  • the present invention was designed for and is particularly adapted for use in the post hydration processing section of an automated contact lens production facility.
  • Contact lenses molded in an automated production line such as that described in EP-A-0 686 491; EP-A-0 686 488; and EP-A-0 605 171 are particularly benefitted by the present invention.
  • FIG. 1 a suitable packaging element 10 is illustrated in a perspective view. This packaging element is more fully described in EP-A-0 604 177.
  • the packaging element 10 may be formed by injection molding or be thermally formed of plastic sheet material, such as polypropylene.
  • the packaging element 10 includes an essentially rectangularly shaped platform portion 12, which may be visually divided into laterally distinct portions 14a and 14b by registration notches 16a and 16b which are formed in opposing sides of the platform portion.
  • the first portion 14a defines a concave recession 24 which is particularly well suited for receiving therein and transporting a contact lens and fluid.
  • the second portion 14b is generally flat, providing an ideal location for contact with a vacuum lifting means in that it provides a stable surface to seat against.
  • the package carrier is further defined by a wall portion 18 which descends at an angle, outwardly and downwardly from the platform portion 12 at one end thereof, forming an angled flange member. Descending downwardly from the corners platform portion 12, at the opposing ends thereof, are a pair of registration flanges 20 and 22, only one of which is visible in the view shown in Figure 1.
  • the registration flanges 20 and 22 are used, in conjunction with the angled flange 18 and registration notches 16a and 16b, to align the packaging element 10 during robotic handling.
  • the notches 16a and 16b are provided on either side of the platform 12 so that they may cooperate with registration pins on various carrier pallets.
  • Flange structures 18, 20, and 22 mate with the topological structure of pallets onto which the packaging elements are disposed, therein providing additional securing means for holding the element on the pallet.
  • the first portion 14a of the platform includes a concave recession 24 which is of an essentially semi-spherical configuration, generally in conformance with a curvilinear shape of a contact lens (not shown).
  • the contact lenses are therefore, adapted to be stored in the recession 24, in a sealed condition while immersed in a suitable sterile aqueous solution, in a manner similar to that described in U.S. Patent No. 4,691,820 to Martinez; which is assigned to the assignee of the present invention, the disclosure of which being incorporated herein by reference thereto.
  • the perpendicular extent of the wall portion 18 which descends outwardly and downwardly from the platform member 12 is equivalent to the height or depth of recession 24 therein providing self alignment of the packaging element.
  • the concave recession 24 also includes a plurality of small gripping marks 26 which are used to assist in holding a contact lens in the centered position in the recession 24 during the removal of deionized water at the deionized water extraction assembly which will be more fully described, with reference to the appertaining Figures hereinafter.
  • the outer edge of the recession 24 includes a raised annular rim 28 which is provided for enhancing the efficacy of the heat sealing of the foil label in the foil sealing assembly which hermetically seals the contact lenses and packaging elements for commercial distribution.
  • a cut-out 30 is used to facilitate gripping the foil wrapper when it is removed by a consumer to access and use the lens contained therein.
  • Pallet 40 includes a first and second parallel rows 42,44 of cavities 46 which are shaped to receive the underside of the recession 24 of the packaging element 10.
  • the parallel rows 42,44 of cavities are separated by a channel 48 which is defined by two walls 50a,50b.
  • the wall corresponding to row 44 descends downwardly and outwardly, the angulation of the slant being specifically set to receive flatly thereon, the descending wall portion 18 of each packaging element 10 disposed on row 44.
  • the outer edge 54 of row 42 is similarly slanted to receive thereon the wall portions 18 of the packaging elements 10 disposed on row 44.
  • the pallet is further provided with a pair of elongated notches 56,58 for receiving the registration flanges 20,22 of the packaging element.
  • the elongated notches 56,58 further provide a positive grip surface for transferring means that lift, rotate, and transport the pallet.
  • the pallet 40 includes registration pins 52 which engage the packaging elements at the lateral edges. These registration pins 52 engage the registration notches 16a,16b of the packaging elements 10 to provide additional accuracy in their registration, specifically with respect to the longitudinal axis of the pallet.
  • the combination of slanted walls 50b and 54, grooves 56 and 58, and the registration pins 52, which each couple with corresponding features of the packaging elements, provide particularly effective means to ensure against rotational skewing.
  • the inspection pallet 10 is further provided with three registration openings 60, on either side of the pallet 40, which are used by means associated with assemblies of the present invention to transport, and lock the pallet in place, during operation thereof.
  • the packaging elements 10 are fabricated in sets of sixteen, and are disposed on pallets 40 in predetermined arrays, typically 2 X 8.
  • the pallets and packages are transported, via a conveyor line, to the deionized water injection assembly in sets of two, oriented to define therebetween an array which is 4 x 8.
  • the deionized water injection assembly 100 is shown in a front side view and a lateral side view.
  • This assembly 100 comprises four separate elements: a water dispensing head 110; a set of coordinated vertically oriented stops 120a,b; a pallet positioning device 130; and a water overflow drain unit 140.
  • the water dispensing head 110 translates up and down with respect to a conveyor line 102 and to the pallets 40 thereon.
  • the coordinated vertically oriented stops 120a,b are utilized to stop the advancing pallets 40, and feed one pair of pallets per cycle.
  • the pallet positioning device 130 receives the pair of advancing pallets 40, advances itself and the pallets horizontally to a first water dispensing location, then to a second dispensing location.
  • the pallet positioning device 130 translates vertically which permits the pallets 40 continue to advance along the conveyor 102.
  • the positioning device 130 reciprocates back into position to receive a next set of advancing pallets 40.
  • the water overflow drain unit 140 is positioned beneath the conveyor line, vertically aligned with water dispensing head 130, for catching waste water from the dispenser.
  • each of the stops 120a,b includes a vertically aligned plate 122 having one of its facial planes perpendicular to the axis of motion of the conveyor line 102.
  • the plate 122 is coupled to a piston/cylinder 124, the selective vertical actuation of which advances the plate 122 into the stream of pallets 40 advancing along the conveyor line 102.
  • the deionized water dispensing head 110 includes a horizontally disposed reciprocating support plate 112.
  • the support plate 112 has sixteen holes 116 arrayed in a 4 x 4 matrix.
  • the top of the plate 112 receives a set of sixteen flexible hoses 114, for example tygon tubing or other fluid conduit, for delivering deionized water to a set of sixteen narrow and elongate teflon tubes 118 which extend downwardly from the bottom of the plate 112 and are particularly well suited to delivering precise doses of deionized water therethrough.
  • Teflon is a particularly desirable material for such a use as water generally does not adhere to teflon surfaces in large droplets which may fall therefrom at inappropriate times in the deposition cycle.
  • the plate 112 is coupled, at a lateral edge, to a piston/cylinder 111, which may be actuated to raise and lower the head 110 (and the teflon tubes 118) in accordance with a predetermined deionized water deposition cycle which is more fully described hereinbelow.
  • a water drain unit 140 Beneath the conveyor line, vertically aligned with water dispensing head 130, is a water drain unit 140 which is so disposed to catch any excess water which may emanate from the dispenser during purge cycle or cycle misfeeds.
  • the water drain unit comprises a basin 142 having a sloped base, therein forming a funnel-like shape, directing water therein toward a hole 144 in the base.
  • the hole 144 is coupled to a drainage tube 146 which carries the drainage water away from the assembly to a remote location.
  • the fourth element of the deionized water injection assembly 100 comprises a pallet positioning device 130.
  • This element receives a pair of advancing pallets 40 and first holds them in position beneath the deposition head 110 in a first position so that the first sixteen recesses 24 of the packaging elements may be filled with deionised water.
  • the pallet positioning device 130 translates horizontally to a second position, thereby repositioning the pallets 40 at a second position beneath the deposition head 110.
  • the second sixteen recesses 40 of the pair of pallets 40 receive a quantity of deionized water.
  • the registration device release the pallets, rises to allow the pallets to advance beneath it, and reciprocates back to the pallet receiving location (the first location).
  • the positioning device comprises a pair of spaced apart arms 131,132 which extend laterally across the conveyor line 102, and which are ideally spaced for receiving and holding pairs of pallets 40 which advance down the conveyor line 102.
  • the arms 131,132 are coupled at their lateral ends 133 to vertically oriented piston/cylinder 134 which raises and lowers the arms 132 in accordance with the timing of the deposition cycle.
  • the arms 131,132 are coupled together via an elongate spar member 135 and a horizontally disposed piston/cylinder 136. Actuation of the piston/cylinder 136 causes the arms 131,132 to move relative to one another. Specifically, arm 131, which is positioned in front of the deposition head, up stream from the deposition head with respect to the flow of the conveyor line 102, remains stationary as the other arm 132 is directed farther downstream from the deposition head 110, therein moving the pair of pallets 40, into the second deposition position.
  • the entire assembly functions in accordance with a predetermined timing schedule, beginning with the advance of a pair of pallets 40 along the conveyor line 102, toward the assembly. Once a pair of pallets 40 have passed the first of the coordinated vertical stops 120a, plates 122 are raised, so that additional pallets 40 may be restrained from continuing into the water dosing location.
  • the two pallets 40 continue to advance until they reach the second of the coordinated vertical stops 120b, at which point the pallet positioning device 130 descends into position holding the pallet in the first deposition position.
  • Deionized water is then injected via the teflon tubes 118 into the first sixteen recesses 24 of the pallets.
  • vertical stop 120b is retracted and the horizontally oriented piston/cylinder 136 of the positioning device 130 is actuated, thereby advancing the pallets 40 to the second deposition position.
  • the arms 131,132 are raised by vertically oriented piston/cylinder 134, and the horizontally oriented piston/cylinder 136 is retracted.
  • vertical stop 120a is lowered to permit the next pair of pallets through the dispensing station, and the second set of vertical stops 120b are raised. After the second pair of pallets have advanced, the vertical stops 120b are raised to stop the following pallets 40 from entering, and the cycle repeats.
  • the packaging elements 10 Once the packaging elements 10 have each received a quantity of deionized water, the packaging elements and pallets are transferred along the conveyor line to a lens loading location where each recess 24 receives a contact lens by a loading assembly described hereinbelow.
  • a contact lens hydration pallet 200 is shown in a top view wherein phantom lines correspond to internal structures of the hydration pallet.
  • the hydration pallet 200 comprises 32 semi-spherical recesses 202 in which contact lenses are transported through a series of extraction stations, which are described more fully in EP-A-0 686 488.
  • the hydration pallet 200 has a plurality of conduits 206 which extend upwardly from the top surface of the pallet. These conduits 206 are coupled, via internal branch conduits 208, to small holes 204, one of which is disposed at the bottom of each recess 202, at the bottom thereof.
  • the holes 204 are thereby coupled in gas and/or fluid flow communication with an external supply, whereby a fluid or gas may be selectively introduced between the surface of the recess 202 and a lens disposed therein.
  • the selective introduction of this gas or fluid, via the hole 204 is used to propel the lenses upward so that they may each adhere to corresponding convex lens attachment surface of the finger elements of the lens transfer assembly as described hereinbelow.
  • the assembly 210 generally comprises a head element 240 and a dual axis linearly translating mounting unit 220.
  • a mounting bracket 222 is coupled at its lower horizontal surface 222a to the head element 240.
  • the mounting bracket 222 is, in turn, mounted to a base element 224, in relation to which, the mounting bracket 222 may be raised or lowered by means of a vertically oriented translation mechanism. It is understood that a variety of means may be employed for the raising and lowering of the mounting bracket 222 including an articulated robot. However, a preferred mechanism comprises an IKO ball screw drive system to reciprocally translate the head from position to position.
  • the base element 224 is mounted to a horizontal track 226, along which it translates in accordance with the actuation of a motive means.
  • the motive means 228 is shown to be a ball screw drive, however, it is understood that a variety of alternative translation means may be employed to provide an equivalent function.
  • the translation means may comprise a hydraulic or pneumatic piston/cylinder device, or it may comprise a scissoring arm assembly.
  • the ball screw is preferred for its accuracy, mechanical simplicity, long term operability, and efficiency.
  • a coupling element 242 is affixed at its upper end to the lower surface of the mounting bracket 222.
  • the lower end of the coupling element 242 is mated to a pair of guide plates 244 which are substantially parallel and held in spaced relation to one another by cross bars 246.
  • a set of four horizontal support beams 248 is Slidably mounted on the cross bars 246, also in spaced apart relation to one another.
  • the support beams 248 slidably mounted on the cross bars 246 so that they may be drawn together or spread apart in accordance with their appropriate positioning.
  • the means by which the support beams 248a-d may be moved relative to one another is provided by a pair of piston/cylinders 250,252.
  • the embodiment of Figure 5b shows the first piston/cylinder 250 couples the two inner beams 248b,c, and the second piston/cylinder 252 couples the two outer beams 248a,d.
  • the second piston/cylinder is mated directly to a bracket 254 on one of the outer beams 248a, and mated to a linkage plate 256 which couples the piston/cylinder 252 to bracket 260 which is attached to outer beam 248d.
  • the first piston/cylinder 250 is coupled directly to brackets 262a,262b which are in turn mated to the two inner beams 248b,c.
  • each support beam 248a-d Extending downward from each support beam 248a-d are a plurality of finger elements 264, to which the lenses adhere during transfer.
  • Selective actuation of the piston/cylinders 250,252 which causes the beams to move relative to one another, causes the relative spacing of the finger elements 264 to be altered.
  • the finger element 264 comprises an elongate shape having a convex lens attachment surface 266, the curve of the surface 266 generally corresponding to the curvature of the concave surface of a contact lens.
  • a central bore 268 extends through the finger 264 from the top 270 to the lens transfer surface 266. This bore 268 is included for the selective ejection of a fluid therethrough, which fluid may be deionized water, as will be discussed below with respect to the deposition of a lens into a corresponding packaging element 40.
  • each finger 264 includes an annular slotted skirt 272 which separates the curvate shape of the lens transfer surface 266 from the generally cylindrical shaft portion 274 of the finger 264.
  • This slotted skirt 272 which includes alternating vertically oriented slots 272a and skirt elements 272b helps retain the lens on the attachment surface 266 and prevents it from sliding, or otherwise moving out of a desired position.
  • the vertically aligned slots 272a are designed to provide a channel through which a fluid or gas which is directed upwardly at the lens transfer surface may flow smoothly.
  • the skirt elements 272b are provided to prevent a contact lens from sliding off the lens transfer surface when said fluid or gas is directed at the surface.
  • a circular mounting disc 271 is disposed about the cylindrical shaft of the finger 264, at a position remote from the tip 266.
  • the mounting disc 271 may be coupled to the upper or lower surface of the corresponding support beam 248, such that the top of the finger 264 may be coupled to an external supply of fluid such as deionized water with the lens transfer surface 266 extending downward.
  • the tops 270 of the fingers 264 are coupled to tubes 273, which are preferably flexible, and which may selectively supply fluids such as air or deionized water to the central bore 268 in accordance with the predetermined operation of the assembly.
  • a hydration pallet is advanced along the lens conveyor line 275 to a position directly beneath the lens transfer assembly 210.
  • the dual axis linearly translating mounting unit 220 lowers the head array 240 so that the lens transfer surfaces of the fingers 264 are positioned directly above the recesses 202 of the pallet.
  • a quantity of air is directed through the conduits 206,208 in the plate. This air floats the contact lenses out of the recesses 202, and onto the lens attachment surfaces 266 of the fingers 264.
  • the lenses and recesses 202 of the pallet have residual deionised water thereon.
  • This deionized water assists the lenses in adhering to the surface 266 of the finger 264 via surface tension. While the lens will adhere to the curved lens attachment surface 266 with or without an additional surfactant, a surfactant may be added to more efficiently wet the surfaces together and promote retention of the lens by virtue of the surface tension of the deionized water and the surrounding atmospheric pressure. In the transfer, it is desirable to position each of the finger tips 266 within 1.5 mm of the lens to ensure a direct and precise transfer.
  • the outer surface of the lens may have bubbles of air, in the deionized, water attached to it. If the bubbles remain, and are not dissolved, or otherwise removed from the lens, subsequent inspection of the optical correctness of the lenses will be compromised.
  • Degassed ionized water is used in the hydration apparatus to minimize bubble formation, and in order to ensure that air bubbles are removed from the surface of the lens, when the head element 240 and fingers 264 are raised, the mounting assembly transports them to a bubble blow off unit 280 disposed between the hydration conveyor line 275 and the packaging element pallet line 102.
  • the bubble blow off unit 280 comprises a plate 284 having a regular array of recesses 282 therein.
  • the regular array of recesses 282 is designed to match the spacing of the fingers 264 of the lens transfer assembly head 240.
  • the base of the recess 282 includes a through hole 286, which forms the mouth of a conduit 288 which extends downward to an air supply means. Selective ejection of air through the conduit is directed at the lens which is adhered to the lens attachment surface 266 of the finger 264.
  • the force of the jet of air may cause the lens to migrate across the attachment surface 266, however, the slotted skirt 272 prevents the lens from sliding more than a portion of one lens radius from the center position.
  • the jet removes the bubbles from the lens surface so that the inspection process will not falsely identify such air bubbles as fabrication errors in the lens itself.
  • the piston/cylinders 250,252 are actuated to bring the beams 248 together.
  • This change in relative distribution of lenses perpendicular to the beams 248 (whereby the four rows of eight fingers are brought closer to one another, but the spatial separation of fingers within the rows remains unchanged) is necessary because the distribution of packaging elements on the inspection pallet 40 is set in accordance with the inspection station apparatus, which is not the same as the relative spacing of the lenses during molding or hydration.
  • the horizontally oriented translation means 228 transports the head element 240 and the lenses to a position above the pallet 40 on conveyor line 102. With the lenses are positioned above their corresponding recesses 202, a quantity of deionized water is discharged from the tip of the finger, via the central bore 268, into the space between the lens and the lens attachment surface. This quantity of deionized water is sufficient to disrupt the surface tension adhesion of the lens to the surface, causing the lens to be carried along with the water into the package element 10.
  • the contact lenses and lens-package elements are carried on the pair of inspection pallets 40, by the conveyor 102 to the next station which is the buffering station.
  • the fingers of the lens transfer assembly then return to their open spatial array, and the head element 240 is reciprocated back to its receiving position above the hydration conveyor line 275, and awaits the next batch of contact lenses.
  • the process of manufacturing contact lenses is in large part determined by the handling requirements of the lenses themselves. For example, one of the most important restrictions around which all of the molded article handling assemblies are designed is that the optical surfaces should not be touched.
  • the handling requirement which is most relevant to the present assembly is that the lenses, once hydrated, must not be allowed to remain dry for more than 15 minutes.
  • the assemblies of the present invention which together form the post lens hydration apparatus, require periodic maintenance and/or refilling with materials used in manufacturing.
  • the primary packaging station the saline solution injector and foil sealing assemblies
  • the performance of other assemblies are susceptible to being interrupted.
  • the molding assemblies need to be kept in continuous operation for proper equilibration which is critical for optimal yield quantities.
  • the ideal position for a buffering station must be one where the lenses remain in an aqueous environment.
  • the buffering station of the present invention is positioned between the lens transfer assembly and the inspection station.
  • the pallets 40 which have been filled with deionized water, and into which contact lenses have been deposited, each define a 2 x 8 array. In pairs, the pallets define a 4 x 8 array.
  • the pairs of pallets are advanced side by side; the elongate axis defined by the columns of 8 recesses, of each pallet being parallel to the direction of motion of the conveyor line.
  • the buffer station comprises first, second, third, and fourth segments 304,308,312,316 of a conveyor line, each of which is disposed for movement of pallets in the same direction.
  • a segregator unit 320 is positioned after the first segment 304, and an integrator unit 340 is positioned before the fourth segment 316.
  • the second and third segments 308,312 run parallel to one another, each beginning at the segregator unit 320 and ending at the integrator unit 340.
  • a first segment 304 of the buffer conveyor line is disposed perpendicularly to the lens transfer conveyor line 102 which advances the pallets from the lens transfer assembly, as set forth above.
  • the end of the lens transfer conveyor line 102 and the beginning of the first segment 304 of the buffer conveyor line, and the lateral pallet transfer unit 306 which transfers the pallets 40 from the former to the latter are shown in a top view.
  • the pairs of pallets 40 reach the end of the lens transfer conveyor 102 they are stopped from advancing by a guide 300.
  • the pallets 40 are then pushed by a push plate 302 from the lens transfer conveyor line 102, onto the first segment 304 of the buffer conveyor line.
  • the pusher plate 302 includes an arm 303 extending from its back portion which is motively coupled to a slide element 305 which is disposed beyond the wall element 300.
  • Selective actuation of the slide element 305 in the forward direction provides the linear lateral motion of the pusher plate 302 and transfers the pallets 40 to the first segment 304 of the buffer conveyor.
  • Reverse actuation of the slide element 305 reciprocates the pusher plate 302 into position to receive the next pair of pallets 40.
  • a variety of mechanisms may be employed which provide the appropriate motion of the pusher plate; examples being a ball screw drive, hydraulic, pneumatic, or air piston/cylinder elements, or mechanical scissoring devices.
  • pairs of inspection pallets 40 are transferred to the first segment 304 of the buffer line, they are translated from a parallel relationship to a tandem relationship, because the segment 304 is oriented perpendicularly with respect to the lens transfer conveyor 102.
  • the pair is now advanced in tandem with one pallet following the other, each having its elongate axis oriented perpendicularly with respect to the direction of motion of the first segment 304 of the buffer conveyor.
  • the pallets 40 are advanced in tandem to the segregator unit 320 which permits alternating pallets 40, for example the first of the pairs, to advance linearly onto a second segment 308 of the buffer conveyor line; the second segment 308 of the buffer conveyor line being co-linear with the first segment 304.
  • a vertical stop mechanism 310a which is similar in form and function to the vertical stop 120 of the deionized water injection assembly, is disposed before the segregator 320 to permit only one pallet of the pair onto the segregator 320.
  • the segregator 320 transfers them to the third segment 312 of the buffer conveyor, which runs parallel to the second segment 308.
  • Vertical stops 310b,310c which are disposed on the second and third segments 308,312 of the buffer conveyor line, are positioned to prevent premature advancement of the pallets 40 on the conveyors until transfer is completed.
  • the segregator 320 is continuously engaged, providing both a constant spacing of individual pallets 40 from one another, and providing a dual track holding line for the pallets 40 during interruptions in the subsequent assemblies of the manufacturing line.
  • the pallets 40 thereby form parallel lines extending along the second and third segments 308,312 for distances which are determined to be sufficient to store the number of pallets 40 which will be produced during normal service interruptions in the manufacturing line, as for example twenty minutes.
  • an integrator unit 340 is provided to merge the two streams of pallets 40 so that they may advance, in a regularly spaced unitary stream, along the fourth segment 316 of the buffer conveyor, to the inspection station.
  • vertical stops 310d,310e are positioned at the ends of the segments 308,312 respectively, and are engaged to ensure that only one pallet 40 enters the integrator at a given time.
  • the integrator 340 remains engaged during normal operation of the manufacturing line, but is disengaged to stop the advance of any further pallets 40 when an interruption occurs. During this time, the pallets 40 which continue to advance from the lens transfer assembly are stored in parallel lines on the second and third segments 308,312 of the buffer conveyor. Once the interruption ends, the integrator 340 is reengaged and merges the stored pallets in a continuous stream.
  • a final vertical stop 310f is disposed at the outlet of the integrator 340 to prevent premature advancement or skewing on the powered conveyor, and to enable spacing between pallets 40 on the fourth segment 316, as they enter the inspection station.
  • FIG. 10 is a perspective view of the segregator unit, particular attention is provided to the features and function of the segregator 320.
  • a housing 321 which is an inverted L-shaped member is mounted to the lateral edge of the conveyor line, at the coupling point of the first and second segments 304,308. Extending outward from the L-shaped member 321 are a pair of substantially parallel guide rails 323. The rails 323 are received by a stationary plate 327 which is mounted to the outside lateral edge of the third segment 312 of the buffer conveyor.
  • a first moving plate 329 is slidably mounted to the guide rails 323 such that the plane of this first plate 329 is aligned vertically and parallel to the direction of conveyor motion.
  • This first plate 329 reciprocates from a first position between the second and third conveyor segments 308,312 and a second position at the stationary plate 327.
  • a second moving plate 331 is similarly mounted to the guide rails 323, and to a motive means (not shown) such that it may be reciprocated from a position at the outside lateral edge of the second conveyor segment 308 to a position between the second and third segments 308,312.
  • the first and second plates 329,331 are maintained in a spaced apart relation such that a pallet 40 may be transferred therebetween, from the first segment 304 to the third segment 312 upon selective reciprocation of the plates 329,331 along the guide rails 323.
  • the reciprocation of the plates 329,331 is selectively controlled such that alternating pallets are transferred to the third segment 312.
  • a variety of motive means and/or coupling means may be utilized for reciprocating the plates 329,331 together, for example the guide rails may comprise a threading and the mounting of the plates 329,331 thereto comprises a nut which may be translated along the guide rails 323 by the rotation thereof.
  • a separate, but equivalent, design includes an air piston/cylinder mounted within the L-shaped member 321 which is coupled to the driving plate 331 and which reciprocates it.
  • a coupling means for example a fixed rod mated to both plates 329,331, must be utilized to slave the motion of plate 329 to the motion of the dive plate 331.
  • FIG 11 is a perspective view of the integrator unit, a detailed description of the features and functions of the integrator unit is provided. Similar in many respects to the segregator unit 320, the integrator is essentially the same device which operates in reverse.
  • a housing element 341 which is L-shaped and mounted to the outside lateral edge of the second segment 312 of the buffer conveyor.
  • a pair of guide rails 343 extend outward from the housing member 341 and are received by a stationary plate 347, mounted to the outside lateral edge of the third segment 312 of the buffer conveyor.
  • a set of spaced apart moving plate 349, 351 are slidably mounted to the guide rails 343 such that the planes of these plates 349,351 are aligned vertically and parallel to the direction of conveyor motion.
  • the second moving plate 351 is coupled to a motive means (not shown) such that it may be reciprocated from a position at the outside lateral edge of the second conveyor segment 308 to a position between the second and third segments 308,312.
  • the first and second plates 349,351 are maintained in a spaced apart relation such that a pallet 40 may be transferred therebetween, from the third segment 312 to the fourth segment 316 upon selective reciprocation of the plates 349,351 along the guide rails 343.
  • the reciprocation of the plates 349,351 is selectively controlled such that alternating pallets, one from the second segment 308 followed by one from the third segment 312, advance to the fourth segment 316.
  • a variety of motive means and/or coupling means may be utilized for reciprocating the plates 349,351 together, for example the guide rails 343 may be threaded matable to a threaded hole or nut in the plates 349,351.
  • a separate, but equivalent, design includes an air piston/ cylinder mounted within the L-shaped member 341 which is coupled to the driving plate 351 and which reciprocates it.
  • a coupling means for example a fixed rod mated to both plates 349,351, must be utilized to slave the motion of plate 349 to the motion of the drive plate 351.
  • FIG. 12 a top view diagrammatic of the present invention is provided.
  • the lens transfer station 299 where the lenses are transferred to the packaging elements on the inspection pallets 40 is sequentially followed by the buffering station 399.
  • the pallets, having advanced through the buffering station are transferred through a conveyor station 499 to the inspection station 599, by a low vibration conveyor assembly as described hereinbelow.
  • Figure 13 is a perspective view of the low vibration transfer assembly which transfers the inspection pallet from conveyor 316 to the inspection station.
  • a pallet 40 has passed through the integrator unit of the buffer assembly and has passed down the fourth segment of the buffer conveyor, it is translated to a staging area 325 as illustrated in previously described Figure 9.
  • an overhead double axis transport carrier reciprocates, picks up the single pallet 40 for transfer to the automatic lens inspection station as illustrated in Figure 13.
  • the overhead transport is a double axis Hauser Transport Mechanism, and is used to isolate the automatic lens inspection system from the remainder of the post-hydration line.
  • the pallet can be gently conveyed to the automatic lens inspection system, and thereby avoid such vibrations which that might otherwise impair the inspection results.
  • the next pallet may be advanced into the staging area to be carried onto the inspection line conveyor.
  • the double axis transport mechanism transports the pallets from the buffer conveyor, where the pallets are advanced at a given speed and spacing, to the inspection line, where the speed of the pallets is substantially slowed to avoid vibration. It is necessary, therefore, for the spacing of the pallets on the inspection conveyor to be substantially closer together so that the inspection conveyor may accommodate the same number of pallets in a given time.
  • the low vibration pallet transfer assembly 400 comprises a pair of pallet grasping plates 402a,402b which are mounted, in spaced relation to one another, to corresponding blocks 404a,404b.
  • One of the grasping plates 402a is slidably mounted to its block 404a such that selective actuation of an extending mechanism (housed within block 404a) widens or reduces the spacing between the two grasping plates 402a,402b.
  • the blocks 404a,404b are mounted to a common wall element 406 which is slidably mounted to a base element 408.
  • a second motive mechanism (also not shown) is disposed within the base element 408 and coupled with the common wall 406 such that the wall 406 can be selectively raised and lowered.
  • the base element 408 is mounted to a horizontal track 410 having a translating means for reciprocating the entire assembly from a position above the staging area 325 to the inspection station conveyor line 420.
  • the low vibration pallet transfer assembly 400 reciprocates to the staging area 325 to receive a pallet 40.
  • the common plate 406 is lowered, thereby positioning the pallet grasping plates 402a,402b adjacent to the lateral edges of the pallet 40.
  • the motive element within the block 402a is actuated to draw the plates closer, therein bringing the inner surfaces of the plates 402a,402b in contact with the pallet 40.
  • the common wall 406 is raised, and the pallet is transported to the inspection station conveyor line, which is disposed perpendicularly to the fourth segment 316 of the buffering conveyor line.
  • the pallet 40 is lowered onto the line and released by actuation of the plate widening mechanism. The pallet is then carried into the inspection station. Once the pallet is transferred to the low vibration lens transfer assembly 400 rises and reciprocates back to the staging area 325 to receive the next pallet 40.
  • the inspection pallets 40 are conveyed through the system as a pulse of light is directed through the lens-packages and contact lenses, and focused on a camera to generate an image of the lens therebelow.
  • the camera includes an array of pixels, each of which generates a respective one electric signal proportional to, or representing, the intensity of the light incident on the pixel. Those electric signals are then digitally processed to determine if the lens is acceptable for consumer use. Suitable procedures for processing or analyzing the electric signals from the pixel array are disclosed in EP-A-0 604 179 and EP-A-O 604 174.
  • the Automatic Lens Inspection System sends a datablock with the vision inspection results to the programmable logic controller used to consolidate the lenses for packaging. This information is used by the lens-package transfer assembly as described below.
  • the pallet is lifted by second double axis overhead transport and placed on conveyor for transport to the deionized water removal station (which is station 699 in Figure 12).
  • the deionized water is removed by a specially configured nozzle, as described in EP-A-0 618 063.
  • the deionized water is used to center the lens within the package carrier during the inspection process, but is removed prior to packaging, to enable a precise dosing of a buffered saline solution in the final package, as will hereinafter be described in detail.
  • the lenses, package carriers and inspection pallet are transported to the lens-package transfer assembly which removes the packaging elements and lenses therefrom, deposits the optically incorrect lens-packages (as determined by the inspection station) on a conveyor for bad lenses, and deposits the correct lens-packages on good conveyor.
  • the assembly 500 comprises a reciprocating support 502 coupled at the lower end of a vertical shaft 504.
  • the shaft 504 is, in turn, coupled at its upper end to a rotation means 506 whereby the shaft 504 and the support 502 may be selectively rotated by 90 degrees in accordance with the predetermined positioning of a pallet 40 or the orientation of the conveyor (see Figure 16) onto which the lens-packages are deposited.
  • the rotating means 506 may comprise an air cylinder having stops which, for example, correspond to a 90 degree rotation so that the shaft may be reciprocated between two orientations which are perpendicular.
  • the rotating means 506 is disposed within a mounting platform 501, which is in turn coupled to a dual axis transport subassembly (the horizontal track thereof is identified as element 503 in Figure 15).
  • the dual axis transport subassembly transports the support 502 from a first location to a second location, for example, from a position above the water extraction conveyor line to a position above the consolidating conveyor line (which is described more fully with reference to Figure 16).
  • a set of resilient bellowed fingers 508 having a generally elliptical shape.
  • the fingers 508 each have an open tip 510 at their lower ends which forms an entrance into a central volume which extends the length of the finger.
  • the upper ends of the fingers 508 are coupled to the vacuum tubes 512 such that the central volume of the fingers are in sealed gas flow relation to tubes 512 which are individually coupled to a vacuum source (not shown).
  • Each tube is separately valved; the valves being independently controlled by a processor in accordance with signals received from the inspection station with respect to which lens-packages contain correct lenses.
  • Selective activation of the vacuum source would, therefore, provide a low pressure suction at the tips 510 of the finger 508.
  • the tips 510 of the fingers may be placed onto a flat surface, therein sealing the central volume, and securing the flat surface to the finger 508.
  • a pallet 40 having lens-packages, from which the deionized water has been removed is transported to the first location, the lens-packages being substantially aligned with the fingers 508 of the first rotating lens transfer assembly 500.
  • the fingers 508 are directed downward until their tips 510 contact the flat surface portion 46b of the packaging element, forming a sealing interface therewith.
  • Selective actuation of the valves controlling the drawing of a vacuum within each finger 508 causes the package elements and lenses to be lifted from the pallet.
  • all of the lens-packages may be removed from the pallet 40 and subsequent actuation of the valves may be utilized to deposit the incorrectly molded lenses on a separate, bad, conveyor, and the optically correct lenses on the good conveyor, or in the alternative, only the good lenses are transferred, and the rejected lenses are later removed from the inspection pallet by an alternative means.
  • This procedure can be used to increase (shorten) the cycle time of the transfer device.
  • the manifold 502 and fingers 508 are rotated 90 degrees by the rotating means 506 while simultaneously being reciprocated upward and laterally by the dual axis transport subassembly.
  • the fingers 508 are repositioned over the consolidating conveyor, at which point the vacuum within the fingers 508 which are holding lens-packages is released, and the lens-packages are deposited on the conveyor.
  • the assembly 500 reciprocates back to extract a new set of lens-packages from the next inspection pallet 40.
  • the first rotating lens-package transfer assembly 500 deposits the optically correct lens-packages onto the consolidating conveyor 602 as shown in Figure 16.
  • the consolidating conveyor comprises a belt-type motive surface 604 onto which the two rows of lens-packages are transported.
  • the conveyor surface 604 is divided into parallel longitudinal channels 605 by a guide wall 606. As shown in Figure 16, the rows of lens-packages may not be regularly distributed on the conveyor surface when they are deposited.
  • the lens-packages are transported along the conveyor until the lead packages contact a moveable gate element 610.
  • the gate element 610 interferes with the continued transport of the lead lens-packages in each of the channels 605.
  • a sensor block is disposed above the conveyor surface 604, at a location upstream from the gate element 610.
  • An additional sensor may be located at a distance wherein a specific number of lens-packages may be aligned therebetween in a staging position 609.
  • the array of lens-packages which is positioned between the wall element 608 and the sensor element 610 in the embodiment illustrated in Figure 16 is 2 x 5.
  • Gate element 610 provides for a controlled flow of only the correct number of lens packages necessary to complete the 2 x 5 array in the staging position.
  • a perspective view of the second rotating lens-package transfer assembly 650 is shown. Once a full 2 x 5 array of lens-packages are disposed in this staging position 609, a second rotating lens-package transfer assembly 650 lowers a set of suction fingers which remove the array, rotates, and transports the lens-packages to a pallet of the saline solution injector and foil sealing assembly.
  • the assembly comprises features which are similar in most respects to the first lens-transfer assembly 500.
  • the assembly includes a support 652 which is mounted to the lower end of a rotating shaft 654.
  • the upper end of the shaft 654 is coupled to a rotating means (not shown) which rotates the support through 90 degrees in the horizontal plane.
  • Extending downwardly from the support 652 is an array of regularly spaced fingers 658, the tips 660 of which are hollow so that a vacuum may be drawn therethrough. This vacuum is used to securely hold the lens-package elements during transport.
  • the fingers 658 which are hollow so as to form a conduit through which the vacuum may be drawn, are coupled to tubes 662, at the support 652 for the purposes of supplying the vacuum pressure to the finger tips 660.
  • the rotating shaft 654 is coupled, through the rotating means, to a mounting platform 651.
  • the mounting platform is, in turn, mounted to a dual axis motive means (track 653 comprises the horizontal axial component along which the mounting platform translates.
  • track 653 comprises the horizontal axial component along which the mounting platform translates.
  • the assembly is positioned above the consolidating conveyor 602, at the staging position 609, as the array of lens-packages is consolidated.
  • the manifold 652 and fingers 658 are lowered by the dual axis motive means.
  • a vacuum is drawn in the finger tips 660 once the lens-packages are contacted in order that a secure grip on the lens-packages may be maintained.
  • the manifold 652 and fingers 658 are then raised, rotated, and translated to a position above the pallet stream of the next assembly.
  • the rotating means and the dual axis motive preferably comprise, respectively, an air cylinder with 90 degree stops, and a pair of perpendicular IKO ball screw mechanisms.
  • Figure 18 is a schematic device layout of the assembly including a conveyor loop 702 having a plurality of pallets 704 spaced therealong.
  • the pallet stream is intermittently driven such that the pallets stop at the various subassembly stations which are sequentially spaced along the conveyor 702.
  • the related assemblies and subassemblies which cooperate to provide saline and heat sealed covers to previously unsealed lens-packages include the second rotating lens-package transfer assembly 650 disposed at the front of the conveyor 704, the saline injector subassembly 750 positioned adjacent to the front of the conveyor, a short distance downstream from the transfer assembly 650, a foil pick and place unit 777 which receives the foil from a printing machine, and a heat seal unit 780 which seals the foil to the packages.
  • Each of the fixed pallets 704 is particularly designed to support a 2 x 5 array of individual lens-packages. It should be appreciated, however, that alternative embodiments of this assembly can be designed, in accordance with the number of fingers of the second lens-package transfer assembly 650, and the size of the staging position 609 of the consolidating conveyor, to accommodate a different number of rows and a different number of packages in each row.
  • the lens-packages are filled with a saline solution which has a tonicity compatible with the human eye.
  • Stationary pallets 704 are advanced, with lens-packages thereon, beneath a horizontal beam 752.
  • the beam 752 is coupled at a lateral end to a mounting base 754 which is adjacent to the conveyor loop 702.
  • a 1 x 5 array of dosing tubes 756 extend downward from the beam 752, and are supplied with saline solution by saline conduits 758, each of which is supplied by a separate dosing pump (not shown).
  • the dosing pumps are actuated so that a precise dosage of saline solution is deposited into the packaging recesses 24. Each contact lens is thereby completely immersed in saline solution.
  • the rate of pumping of saline solution and the diameter of each dosing tube 756 is chosen such that no saline solution splashes from any of the recesses of the packages, which is very important as any saline solution splashed onto the annular rim 28 would interfere with subsequent foil sealing operations.
  • the optical verification probes may be mounted in front of the saline injector subassembly to verify that lens-packages are present in the advancing pallet 704 so that the dosing tubes 756 do not dispense saline solution into empty pallets.
  • Additional sensors may be similarly mounted along the conveyor, downstream from the saline injector 750, to detect the presence of the proper measured dose of saline solution in each lens-package.
  • a variety of such sensors are available, and are taught in EP-A- claiming priority from U.S.S.N. 08/431,891 (Attorney Docket No.P15589EP).
  • the senor may be a reflective sensor as is commercially available from Omron, or it could be a proximity sensor or could be a fiber optic probe, as commercially available from Keyence as model 24W-V25R, used with an amplifier, model 24W-AA1C.
  • Each detector checks and verifies for a proper height of saline solution in each lens-package.
  • a pair of strips of laminar foil are placed over the 2x5 array of package bases, each foil strip covering a 1x5 column of packaging elements.
  • the foil strips have printed thereon all identification indicia required for the final package.
  • the laminar top cover sheets are produced by a foil labeling machine pursuant to the disclosure of EP-A-0 646 471.
  • the foil labeling machine extends at a right angle to the linear packaging machine, as indicated by the FOIL arrow in Figure 18.
  • the pair of foil strips are received from the labeling machine and placed by a foil pick and place unit over the top of each 1x5 row of the 2x5 array of package bases.
  • An optional mechanical chucking station 777 positions each foil strip to ensure that it is properly positioned and aligned relative to the lens-packages in the pallet 704.
  • a subsequent cover presence verification station may be used to verify the correct general positioning of each foil strip.
  • the foil strips are heat sealed to the lens-packages. More specifically, a set of heated seal heads, mounted at spaced intervals along the length of heating head plate 782, and supported by a pneumatic cylinder or press 784, presses the foil strips against the lens-packages such that the foil and the annular rims 28 of the packaging elements are squeezed between the heated seal heads and the pallet 704.
  • a final optical inspection station may be located downstream of the heat sealing station 780, including a plurality of optical detector probes for examining the outer edges of each sheet of laminated foil strips on the array of lens-packages to ascertain that the foil is properly and precisely positioned and heat sealed relative to the array of lens-packages.
  • a robotic assembly 790 having a plurality of vacuum suction cups removes the sealed 1x5 array of packages from the pallet 704, and transports them to an output position.
EP96303006A 1995-05-01 1996-04-30 Procédé et dispositif de transport, d'inspection et d'emballage de lentilles de contact après l'hydratation Expired - Lifetime EP0741079B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US432957 1995-05-01
US08/432,957 US5649410A (en) 1994-06-10 1995-05-01 Post-hydration method and apparatus for transporting, inspecting and packaging contact lenses

Publications (3)

Publication Number Publication Date
EP0741079A2 true EP0741079A2 (fr) 1996-11-06
EP0741079A3 EP0741079A3 (fr) 1997-07-02
EP0741079B1 EP0741079B1 (fr) 2000-01-05

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Country Link
US (1) US5649410A (fr)
EP (1) EP0741079B1 (fr)
JP (1) JP4059935B2 (fr)
AT (1) ATE188429T1 (fr)
AU (1) AU692692B2 (fr)
CA (1) CA2175308C (fr)
DE (1) DE69605970T2 (fr)
SG (1) SG79918A1 (fr)
TW (1) TW380211B (fr)

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US7213382B2 (en) 1998-12-21 2007-05-08 Johnson & Johnson Vision Care, Inc. Heat seal apparatus for lens packages
WO2008053587A1 (fr) * 2006-10-27 2008-05-08 Menicon Co., Ltd. Système et procédé destinés à transférer des lentilles hydratées sur une chaîne automatisée
WO2009058822A1 (fr) * 2007-10-31 2009-05-07 Novartis Ag Système de dosage d'additif et de solution saline et procédé pour un conditionnement de lentille de contact
US9296160B2 (en) 2009-09-11 2016-03-29 Coopervision International Holding Company, Lp Method for moving wet ophthalmic lenses during their manufacture
US9718625B2 (en) 2015-11-20 2017-08-01 Greatquo Technology Co., Ltd. Automatically cycling detecting-and-sorting device
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IT201800009469A1 (it) * 2018-10-16 2020-04-16 Ima Industria Macch Automatiche Spa Macchina confezionatrice per lenti a contatto.

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US7213382B2 (en) 1998-12-21 2007-05-08 Johnson & Johnson Vision Care, Inc. Heat seal apparatus for lens packages
WO2004026691A1 (fr) * 2002-07-02 2004-04-01 Johnson & Johnson Vision Care, Inc. Appareil pour mettre sous emballage des lentilles de contact
WO2008053587A1 (fr) * 2006-10-27 2008-05-08 Menicon Co., Ltd. Système et procédé destinés à transférer des lentilles hydratées sur une chaîne automatisée
US7637085B2 (en) 2006-10-27 2009-12-29 Newman Stephen D System and method for transferring hydrated lenses on an automated line
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CN109421963A (zh) * 2017-08-21 2019-03-05 晶硕光学股份有限公司 水平式装盒机自动投片验片机构
CN109421956A (zh) * 2017-08-21 2019-03-05 晶硕光学股份有限公司 水平式装盒机自动验片机构
CN109421963B (zh) * 2017-08-21 2020-11-03 晶硕光学股份有限公司 水平式装盒机自动投片验片机构
CN109421956B (zh) * 2017-08-21 2020-11-10 晶硕光学股份有限公司 水平式装盒机自动验片机构
IT201800009469A1 (it) * 2018-10-16 2020-04-16 Ima Industria Macch Automatiche Spa Macchina confezionatrice per lenti a contatto.

Also Published As

Publication number Publication date
AU692692B2 (en) 1998-06-11
MX9601644A (es) 1997-07-31
DE69605970D1 (de) 2000-02-10
CA2175308A1 (fr) 1996-11-02
JP4059935B2 (ja) 2008-03-12
AU5200696A (en) 1996-11-14
TW380211B (en) 2000-01-21
US5649410A (en) 1997-07-22
EP0741079B1 (fr) 2000-01-05
EP0741079A3 (fr) 1997-07-02
DE69605970T2 (de) 2000-06-29
CA2175308C (fr) 2006-11-28
ATE188429T1 (de) 2000-01-15
SG79918A1 (en) 2001-04-17
JPH0924914A (ja) 1997-01-28

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